Concrete forming systems and methods

ABSTRACT

Systems and methods for constructing concrete foundations are provided which allow for rapid and high-precision placement and alignment of anchor bolts across large distances. A frame system is constructed outside of an excavation and then suspended, using supports, over an excavation. The frame system can include a frame having one or more templates for anchor bolts, a form suspended from the frame, and a mat and cage assembly tied to the frame. The frame system can be aligned in proper position and the anchor bolts placed in the frame system before the concrete is placed. In this way, the anchor bolts can be cast in place as the footing is placed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.14/216,827, which is now a U.S. Pat. No. 9,937,643, filed Mar. 17, 2014,which is a continuation under 35 U.S.C. § 120 of InternationalApplication No. PCT/US2012/055628, filed Sep. 14, 2012 (and published bythe International Bureau as WO 2013/040495 on Mar. 21, 2013), whichclaims the benefit of U.S. Provisional Patent Application No.61/535,875, filed Sep. 16, 2011. Each of the above-referencedapplications is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION Field of the Invention

This application relates to concrete construction, and moreparticularly, to systems and methods for constructing concrete footings.

Description of the Related Technology

Concrete footings are structural members that transmit the concentratedloads of an overlying structure to the soil below. These members aregenerally constructed of steel-reinforced, concrete and are formed invarious shapes and sizes. A footing typically includes one or moreanchor bolts extending from the top of the footing, which serve toconnect the footing to vertical supports for the overlying structure.

Footings are normally cast directly into an excavation formed in thesoil. To build a spread footing, a mat (i.e., a metal framework toreinforce the bottom portion of the footing) is laid down into theexcavation, and a cage (i.e., a metal framework to reinforce the upperportion, also referred to as the “pier” or “column” of the footing) isset on top of the mat and secured in position. Concrete is then placedover the mat and allowed to harden. The upper surface of the hardenedconcrete is then finished to produce a flat surface upon which thecolumn can be formed. Next, a column form is placed, over the cage,inside the excavation, and concrete is placed into the form to build upthe column. After the column concrete is placed, anchor bolts areinserted into the wet concrete at the top of the column and theirpositions are adjusted as needed. The column is then allowed to harden,after which the upper surface of the column is finished smooth.

SUMMARY

The systems and methods of the present invention have several features,no single one of which is solely responsible for its desirableattributes. Without limiting the scope of this invention as expressed bythe claims which follow, its more prominent features will now bediscussed briefly. After considering this discussion, and particularlyafter reading the section entitled “Detailed Description of CertainInventive Embodiments,” one will understand how the features of thisinvention provide several advantages over traditional cathetersecurement systems.

In one aspect, a method of forming a concrete footing in an excavationcomprises providing a frame assembly, the frame assembly comprising aframe configured to extend over the excavation from a first side of theexcavation to an opposing second side of the excavation; a form coupledto the frame, the form, configured to define at least part of the shapeof the concrete footing; a reinforcement structure configured toreinforce concrete, at least part of the reinforcement structure beingdisposed within the form; and a template defining an inbed pattern overthe form. The method further comprises coupling at least one inbed tothe template, positioning the frame assembly over an excavation suchthat at least part of the form and at least part of the reinforcementstructure are suspended in the excavation, and placing concrete into theform. Concrete can be placed into the form until at least a lowerportion of the at least one inbed can be surrounded by concrete. Thereinforcement structure can be releasably coupled to the frame. Themethod can further comprise separating the frame and the form from theconcrete footing. The frame and the form can remain coupled, to oneanother as they are separated from the concrete footing. The method canfurther comprise forming a second concrete footing in a secondexcavation using the frame assembly. The at least one inbed can be oneor more anchor bolts, or any other type of inbed which may be used, inconcrete construction. Positioning the frame assembly over an excavationcan comprise placing the frame assembly on supports disposed on thefirst and second sides of the excavation. The supports can be set tograde before the frame assembly is placed on the supports.

In another aspect, an assembly for use in forming a concrete footing inan excavation is provided. The assembly comprises a frame configured toextend over the excavation from a first side of the excavation to anopposing second side of the excavation; a form coupled to the frame, theform configured to define at least part of the shape of the concretefooting; a reinforcement structure configured to reinforce concrete, atleast part of the reinforcement structure being disposed within theform; and a defining an inbed pattern over the form. The frame isconfigured such that the form and the reinforcement structure can besuspended from the frame. The assembly can further comprise at least oneinbed, the at least one inbed being releasably coupled to the template.The frame can include at least one opening through which concrete can beplaced into the form, at least when the form is suspended from theframe. The reinforcement structure can be releasably coupled to theframe. The assembly can be configured to allow separation and removal ofthe form and the frame from the concrete footing without requiringseparation of the form from the frame. The template can be removablycoupled to the frame. The frame can comprise at least one attachmentmember configured to couple to the frame and the form. The attachmentmember can be disposed vertically below the template and spaced apartvertically from the template by a sufficient distance to allow workers'hands to access the space vertically between the attachment member andthe template. The assembly can further comprise first and secondsupports configured to support the frame over the first and secondsides, respectively, of the excavation, the supports being adjustable soas to adjust at least the height of the frame over the excavation.

In another aspect, an assembly for use in forming concrete footingscomprising means for defining the shape of a concrete pier, means forreinforcing concrete, the reinforcing means being at least partiallydisposed within the shape-defining means, means for defining an inbedpattern over the shape-defining means, and means for suspending theshape-defining means and the reinforcing means over an excavation. Theassembly can further comprise means for removing the shape-definingmeans and the suspending means from a formed concrete footing withoutseparating the shape-defining means from the suspending means.

In another aspect, a method of forming a concrete footing in anexcavation comprising placing a form, a template, a concrete reinforcingstructure, and one or more inbeds into an excavation simultaneously.These components can be placed in the excavation simultaneously becausethe positions of these components can be fixed with respect to oneanother, at least during this step. Placing these components into anexcavation can include suspending the form and/or the concretereinforcing structure from a frame or other supporting structure. Insome embodiments, placing these components into an excavationsimultaneously can result in the form being positioned vertically at thedesired elevation for the particular construction site. The method alsoincludes adjusting the horizontal position of the form, the template,the reinforcing structure, and the inbed(s). The horizontal positions ofthese components can be adjusted simultaneously, as the positions ofthese components can be fixed with respect to one another, at leastduring this step. The process also includes placing concrete into theform. Placing concrete into the form can include pouring concretethrough one or more openings in the frame assembly such that theconcrete enters the form. Concrete can be placed until it reached adesired, position with respect to the form, at which point the top ofthe concrete is also at a desired elevation for the construction site.Optionally, the process can also include releasing the inbeds from thetemplate, separating the form from the hardened concrete, and removingthe form and template from the excavation.

In embodiments, a frame can be used to position inbeds over anexcavation at the correct elevation and correct horizontal alignment,with all the other components that will be used to construct a footing(aside from the concrete itself) already connected to and suspended fromthe frame as the inbeds are positioned. In this way, the inbeds can beproperly positioned before any concrete is placed. Also, since all ofthe other components that will form the footing are suspended from theframe below the inbeds as the inbeds are positioned, embodiments avoidthe risk of any potentially interfering structures (forms, rebar, etc.)disturbing the positions of the inbeds. By assembling together the form,concrete reinforcement structure, inbed template, and inbeds, andsuspending the entire assembly over an excavation together, the processfor constructing a concrete footing with properly positioned anchor bedscan be greatly simplified.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a frame system configured in accordancewith an embodiment,

FIG. 2A is a side elevation of the mat and cage assembly shown in FIG.1.

FIG. 2B is a top plan view of the mat and cage assembly shown in FIG.2A.

FIG. 3A is a top plan view of the frame shown in FIG. 1.

FIG. 3B is a side cross-sectional view of the frame shown in FIG. 3A,taken along line 3B-3B.

FIG. 3C is another side cross-sectional view of the frame shown in FIG.3A, taken along line 3C-3C.

FIG. 3D is a top plan view of the frame shown in FIG. 1, with thetemplate members removed to better illustrate the attachment members.

FIG. 4 is a perspective view of the form shown in FIG. 1.

FIG. 5 is a schematic exploded side view of the frame system shown inFIG. 1, shown without the ties.

FIG. 6A is a schematic side view of the frame system shown in FIG. 5,shown assembled and with the frame tied to the mat.

FIG. 6B is a partially cut away cross-sectional view of the system shownin FIG. 6A, taken along line 6B-6B and illustrating one example of how aframe can be coupled to a form.

FIG. 6C is a perspective view of one example of a bolt clip that can beused in the system shown in FIG. 6A.

FIG. 7 is an illustration of one step in a process of constructingconcrete footings in accordance with an embodiment, using the framesystem illustrated in FIG. 1.

FIG. 8A is a side sectional view illustrating a frame system suspendedin an excavation, in accordance with one embodiment.

FIG. 8B is a side sectional view illustrating a frame system suspendedin an excavation, with stabilizing pins installed in the excavation inaccordance with another embodiment.

FIG. 8C is a top plan view further illustrating the frame system andstabilizing pins shown in FIG. 8B.

FIG. 8D is a top plan view of a frame system suspended over anotherexcavation, in accordance with a further embodiment.

FIG. 8E is a perspective view of a form adapted for monolithic placementof concrete in a spread footing, in accordance with another embodiment.

FIG. 9A is a perspective view of a grade beam assembly configured foruse with an embodiment.

FIG. 9B is a side view of the grade beam assembly shown in FIG. 9A.

FIG. 9C is a partially cut away top view of the grade beam assemblyshown in FIG. 9A.

FIG. 10A is a perspective view of a hopper configured in accordance withan embodiment,

FIG. 10B is an illustration showing the hopper of FIG. 10A in use with aframe system, in accordance with an embodiment.

FIG. 11A is a side sectional view illustrating a frame system suspendedin an excavation, in accordance with another embodiment.

FIG. 11B is a top plan view illustrating the system of FIG. 11A.

FIG. 11C is a close-up side view illustrating in further detail theportion of FIG. 11A indicated by line 11C-11C.

FIG. 12 is a side sectional view illustrating a frame system suspendedin an excavation, in accordance with another embodiment.

FIG. 13 is a side detail view illustrating another example of how aframe can be coupled to a form, in accordance with an embodiment.

FIG. 14 is a perspective view illustrating another example of a frameconfigured in accordance with an embodiment.

FIG. 15 is a process diagram illustrating a method for forming concretefootings in accordance with an embodiment.

FIG. 16 is a process diagram illustrating a method for forming concretefootings in accordance with another embodiment.

DETAILED DESCRIPTION OF CERTAIN INVENTIVE EMBODIMENTS

With conventional construction methods, proper alignment of anchorbolts—both within an individual concrete footing, as well as from onefooting to the next—is an extremely time- and labor-intensive process.Embodiments of the invention provide systems and methods forconstructing footings which allow anchor bolts to be cast in place asthe footing is placed. Embodiments thus allow footings to be constructedfar more rapidly than with conventional methods while facilitatinghigh-precision placement of anchor bolts.

In some embodiments, a frame system is constructed outside of anexcavation and then suspended, using supports, over an excavation. Theframe system can include one or more templates for anchor bolts. Theframe system can be aligned in proper position and the anchor boltsplaced in the frame system before the concrete is placed. In this way,the anchor bolts can be cast in place as the footing is placed.

FIG. 1 is a perspective view of a frame system 100 configured inaccordance with an embodiment. As shown in FIG. 1, the frame system 100generally includes a frame 102, a form 104, and a mat and cage assembly106. The frame 102 and the mat and cage assembly 106 can be tiedtogether by ties 108. The ties 108 can include, for example, wires orcables. The frame 102 can include one or more elongate members 110 andone or more cross-members 112 extending between the elongate members110. The frame 102 can also include one or more template members 114extending between the elongate members 110. Each of the template members114 can include one or more openings or holes 116 through which one ormore inbeds 117, such as anchor bolts, may be placed. The inbeds 117 canbe releasably secured to the template members 114 in any suitablefashion. For example, in some embodiments, the inbeds 117 can be securedto the template members 114 by inserting each inbed 117 through a hole116 in the template and removably securing the inbed 117 to the template114 using a nut. In embodiments, the inbeds 117 need not be connected inany way to the mat and cage assembly 106. The template members 114 canbe removable and/or replaceable within the frame 102. For example, asshown in FIG. 1, the template members 114 can be removably coupled tothe frame 102 using bolts. In addition, the position of the templatemembers 114 can be adjustable within the frame 102. In otherembodiments, the template members 114 can be permanently coupled (forexample, welded) to the frame 102.

As also shown in FIG. 1, the frame system can include one or moreattachment members 118 configured to releasably couple the frame 102 tothe form 104. The attachment members 118 can be configured to supportand distribute the weight of the form 104 as the form is suspended fromthe frame 104. The attachment member 118 can also be configured to berigid in both the longitudinal and transverse directions, so that itresists bending as it supports the weight of the form 104. In theembodiment illustrated in FIG. 1, the attachment member 118 includes alength of angle that forms a flange on the inward-facing surfaces of theelongate members 110, generally below the template members 114. Invarious embodiments, the attachment members 118 can be integrally formedwith the elongate members 110, permanently coupled (e.g., welded) to theelongate members 110, or removably coupled (e.g., bolted) to theelongate members 110.

The frame 102 can be formed from any material suitable for its intendedpurposes of supporting the weight of the form. 104 and the mat and cageassembly 106 and suspending the form 104 and the mat and cage assembly106 in an excavation. For example, the frame 102 can be formed frommetal, such as aluminum C-channel. In some embodiments, the frame 102(and/or any of its subcomponents) can be formed from 4 inch C-channel,with an overall length of approximately 10 feet and a spacing of about 2feet between the elongate members 110. In other embodiments, the framecan have any suitable shape and dimensions for the particularapplication, taking into account the size of the excavations and theform(s) that will be suspended from the frame. For example, the framecan have a length of about 5, 6, 7, 8, 9, 10, 15, or 20 feet, or alength greater than, less than, or within a range defined by any ofthese numbers. Also for example, the frame can have a width of about 1,2, 3, 4, 5, 6, 7, 8, 9, or 10 feet, or a width greater than, less than,or within a. range defined by any of these numbers. Also for example,the frame can have a height of about 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10inches, or a height greater than, less than, or within a range definedby any of these numbers. The form 104 can be formed from any suitablematerial, such as, for example, wood, cardboard, wax-impregnatedcardboard, and/or plastic. The form 104 can be rectangular orcylindrical in cross-section, or can have any other shape suitable forits intended purposes of defining the shape of a concrete pier andcontaining placed concrete as it hardens. In some embodiments, the form104 can include two halves which can be clamped (or otherwise coupled)together as unset concrete is being placed into the form. The halves canthen be separated from, one another (or “cracked”) and removed from theconcrete once the concrete has hardened. In some embodiments, the form104 can be a SONOTUBE® form, available from Sonoco Products Company ofSouth Carolina, USA. The mat and cage assembly 106 can comprise anysuitable material, such as, for example, rebar, and can be formed usingknown methods. Although illustrated in FIG. 1 with two template members114 having two openings 116 each (for a total of four inbeds), otherembodiments can include 1, 2, 3, 4, or more template members, eachdesigned to accommodate 1, 2, 3, 4, or more inbeds, in any desiredpattern, including rectangular, circular, regular, or irregularpatterns, as desired for a particular application. In addition, theinbed(s) 104 can be any type of inbeds that may be used, in concreteconstruction, including anchor bolts, pipes, tubes of anycross-sectional shape, C-channel, or any other type of inbed.

FIG. 2A is a side elevation of the mat and cage assembly 106. FIG. 2B isa top plan view of the mat and cage assembly 106. The assembly 106includes a mat 120 and a cage 122. The mat 120 can include tied rebarconfigured to reinforce concrete in the lower portion of a footing, andthe cage 122 can include tied rebar configured, to reinforce the upperportion (or pier) of a footing.

FIG. 3A is a top plan view of the frame 102, illustrating the elongatemembers 110, the cross-members 112, and the template members 114. FIG.3B is a side cross-sectional view of the frame shown in FIG. 3A, takenalong line 3B-3B, illustrating the openings 116 in the template members114. FIG. 3C is another side cross-sectional view of the frame shown inFIG. 3A, taken along line 3C-3C, illustrating openings 119 in theattachment members 118. The openings 119 can be configured to align withcorresponding openings in the form 104, allowing the frame 102 and theform 104 to be removably coupled to one another, for example using boltsor other types of fasteners. FIG. 3D is a top plan view of the frameshown in FIG. 1, with the template members 114 removed to betterillustrate the attachment members 118 and openings 119. As illustratedin FIG. 3D, the openings 119 can have an elongate shape. FIG. 4 is aperspective view of the form 104, illustrating openings 105 in flange103 of the form 104.

FIG. 5 is a schematic exploded view of the frame system 100, shownwithout the ties 108. FIG. 6A is a schematic side view of the framesystem 100, shown assembled and with the frame 102 tied to the mat andcage assembly 106. As shown in FIG. 6A, the frame system 100 can includecoupling members 124, such as, for example, bolt clips, which can beconfigured to removably couple the frame 102 to the form 104.

In some embodiments, a frame system can be assembled above ground,outside of any excavations and, if desired, before any excavations areformed. Assembly of the frame system can include providing a frame, forexample as described above in connection with FIG. 1. The frame caninclude one or more longitudinally-extending structural members, withlaterally-extending structural members joining the longitudinal members,for example as illustrated above in connection with FIG. 1. The framecan also include one or more templates extending between thelongitudinal members. The template(s) can include holes through whichanchor bolts can be placed in a desired pattern or spacing.

Assembly of the frame system can also include forming a mat and a cage,for example using a rebar tying machine. The size and shape of the matand cage can be determined using known methods. The cage and mat canthen be tied together, also according to known methods. Next, a form(which may also be referred to as a can or cylinder) can be coupled tothe frame. The form can be coupled to the frame with the upper end ofthe form positioned directly under the template(s), with the holes inthe template(s) aligned over the top of the form. The form and frame canbe coupled in any suitable manner to allow the form to be suspended fromthe frame in a stable fashion, without unwanted movement of the form.For example, with reference to FIG. 6B, the form 104 and frame 102 canbe coupled to one another by aligning the openings 105 in the flange 103of the form 104 with the openings 119 in the attachment member 118 ofthe frame 102, and installing a fastener, such as a bolt 125 and a nut126, through the openings 118 and 105. In some embodiments, the bolt 125can be a large-threaded bolt so as to resist damage through multipleuses. The bolt clip 124 and the attachment member 118 can serve todistribute forces in the flange 103 in the region of the holes 103. FIG.6C illustrates the bolt clip 124 in further detail.

Next, the form (along with the frame to which it is coupled) can beplaced over the cage, either by hand or using suitable equipment.Finally, the mat can be tied, to the frame, for example using wires orcables. The mat and frame can be tied together at any suitable locationsalong the mat and/or frame and in any suitable fashion to lend stabilityto the frame system. Finally, anchor bolts can be placed in thetemplate(s), at the top of the form. In this way, the anchor bolts aresuspended (through the template(s)) in position at the top of the form,before the form and frame are set in an excavation and before anyconcrete is placed.

In some embodiments, one or more footings can be constructed using aframe system, such as the frame system 100 described above. One suchembodiment is described with reference to FIG. 7. First, a constructionsite can be prepared according to known methods, for example using hubsand stakes with standard surveying equipment to define the desiredexcavation and anchor bolt layout. Next, one or more excavations 200 canbe dug out using suitable equipment, such as, for example, a backhoe.The excavations can be compacted at the bottom to eliminate crumbs. Agrade rod can then be placed in each excavation to check elevation.

Next, grade pins 204 can be set in the ground, outside of eachexcavation 200. The grade pins can be set using suitable equipment, suchas a backhoe. In some embodiments, the grade pins 204 can be steel pins,such as ¾″-1″ diameter steel pins. In some embodiments, as illustratedin FIG. 7, the grade pins 204 can be set on opposing sides of eachexcavation 200, just in from the corners of each excavation 200.

Once the grade pins 204 are set, grade beams 206 can be set at anappropriate elevation on the grade pins 204, on opposing sides of eachexcavation 200. The appropriate elevation can be determined based on thedesigned finished elevation of the pier (that is, the finished elevationof the foundation) that will be installed. In some embodiments, a lasercan (e.g., a laser beacon) can be used to set the grade beams 206 at theappropriate elevation. The grade beams 206 can be, for example, 2″×8″beams made of wood or any other material. The grade beams 206 can besecured to the pins 204 using screws or other suitable fasteners. Next,the centers of the grade beams 206 can be marked. The centers can bemarked in any suitable fashion, for example using survey equipment, suchas a digital theodolite. A grade rod can be used to check the elevationof the grade beams 206. If desired, multiple excavations 200 can beprepared in this manner before proceeding to the next step.

Next, as illustrated in FIG. 8A, the pre-assembled frame system 100 canbe set in the excavation 200 (either by hand, or using machinery), withthe ends of the frames 102 resting on the grade beams 206. In this way,both the form 104 and the mat and cage assembly 106 are suspended in theexcavation 200, instead of resting on the bottom of the excavation 200(or on supports at the bottom of the excavation) as in conventionalmethods. In embodiments, setting the frame system 100 in the excavationon the grade beams 206 can result in the top of the form 104 (or apre-selected “top-of-pier” location disposed along the height of theform) being positioned, at the desired elevation for the constructionsite, without requiring any further vertical adjustment of the form 104,template 114, or inbeds 117. If desired, multiple frame systems 100 canbe set in multiple excavations 200 in this step.

Then, the position of frame systems 100 in a series of excavations 200can be checked and adjusted if necessary. The lateral position of aframe system 100 can be checked, for example using the marked centers ofthe grade beams 206 to make sure that the frame system is in theappropriate lateral position and moving the frame system 100 laterallyif necessary. In a series of frame systems 100, the lateral positionscan be adjusted in this manner to ensure that the each frame system 100in the series is aligned in the longitudinal direction. Also, thespacing between adjacent frame systems 100 (i.e., center-to-center ortemplate-to-template (e.g., end-to-end or side-to-side) spacing ofadjacent frame systems 100 in the longitudinal direction) can bechecked, for example using tack lines to pull distances from a hub andmoving the frame systems 100 longitudinally if necessary.

When each frame system 100 is properly positioned in its correspondingexcavation 200, form oil can be sprayed on the form 104, and flowableconcrete can be placed into the form 104 until the concrete covers themat 120 at the bottom of the excavation 200 and reaches the lower end ofthe form 104 to create the footing. In some embodiments, as illustratedin FIGS. 8B and 8C, one or more stabilizing pins 210 can be insertedinto the soil at the bottom of the excavation before the concrete isplaced, in suitable locations about the mat 106 (such as, for example,the corners of the mat 106), to limit or prevent movement of the mat asconcrete is placed. The pins 210 can be removed once the concrete isplaced, cleaned, and re-used. In some embodiments, the pins 210 can be,for example, ⅝ inch diameter smooth steel bars.

At this stage, the placed concrete can be allowed to set up for asuitable time, such as, for example, between 2 and 4 hours or more. Theappropriate time can vary depending on temperature, humidity, and theparticular concrete mix. Then, without needing to finish the uppersurface of the placed concrete, additional concrete can be placed intothe form 104 to create the pier. In this way, the anchor bolts or otherinbeds (which are suspended from the template(s) 114 in the frame 102 atthe top of the form 104) are cast in place, having been properlypositioned when the frame system 100 was properly positioned in theexcavation 200.

In some embodiments, the concrete for the footing and the pier can beplaced monolithically, that is, without waiting for the footing concreteto set up before placing the pier. In some such embodiments, for exampleas illustrated in FIG. 8E, a flange 107 can be provided at the bottom ofthe form 104 to help facilitate such monolithic placement. The flange107 can encircle the bottom of the form 104, sloping downward somewhatas it extends away from the form so as to provide additional structuralsupport for the flowable concrete as it is monolithically placed. Theflange 107 can be fastened to the form 104 in any suitable fashion,including, for example, using bolts. The flange 107 can be formed fromany suitable material, and can have any suitable dimension and slopeselected for the viscosity of the concrete being used. For example andwithout limitation, in some embodiments, the flange can extend about 4inches to about 6 inches outward from the form and slope downward 1 inchover that length. In some embodiments, the footing concrete can beplaced through the form and the flange, vibrated, and then the pierconcrete can be placed immediately afterward, without waiting for thefooting to set up.

Next, the upper surface of the formed pier can be finished smooth,according to known methods. In some embodiments, the provision of aspace vertically between the template members 114 and the attachmentmembers 118 can allow working space at the top of the formed pier, sothat hands and tools can access the top of the formed pier while theframe system 100 is still in place. The concrete can then be allowed toharden completely, for example, for between 3 and 16 hours or longer. Insome embodiments, the concrete can be configured to harden more rapidly,e.g., within 4 to 6 hours, or faster.

When the concrete has fully hardened, the frame 102 and the form 104 canbe removed from the pier. In some embodiments, the removal can involveclipping of the ties 108 which connected the mat 120 to the frame 102and removal of the nuts (or other structure) which secured the anchorbolts 116 (or other inbeds) to the template members 114. The removal canalso involve loosening of the nuts 126 which secure the form 104 to theframe 102 (see, e.g., FIG. 6B). Once the nuts 126 are loosened, thebolts 125 can travel in the elongated openings 119 of the attachmentmembers 118 (see, e.g., FIG. 3D), allowing the parts of the form 104 tobe cracked apart and separated from the formed concrete, withoutnecessarily having to separate the form 104 from the frame 102. Ofcourse, if desired, the nuts 126 and bolts 125 can be removed entirely,so that the form 104 and frame 102 can be separated before or during theremoval of the form 104 from the formed pier. The top of the pier can berubbed and the anchor bolts can be cleaned.

Optionally, the frame 102 and form 104 can be cleaned and re-assembledwith a new mat and cage assembly 106, for example as described above, toconstruct another frame system 100 for use in another excavation 200.Once all of the footings have been cast, the excavations 200 can bebackfilled, compacted, and cleaned according to known methods.

As illustrated in FIG. 8D, embodiments can also be used to advantage notjust in constructing spread footings, but also in the construction ofother types of footings, such as a drilled pier in a drilled circularexcavation 230. Embodiments can also be used in constructing bellfootings and other types of concrete structures.

With, reference now to FIGS. 9A-9C, some embodiments can employ otherstructures besides conventional grade beams 206 and pins 204 to supporta frame system 100 over an excavation. FIGS. 9A, 9B, and 9C showperspective, side, and partially cut away top views, respectively, ofgrade structures 300 that can be formed entirely of metal. Thestructures 300 can include grade pins 304 and a beam member 306 formedof metal, such as aluminum C-channel. The beam member 306 can be coupledto the grade pins 304 using one or more fasteners 308. In someembodiments, as illustrated in FIGS. 9A-9C, the fasteners can be U-bolts308 which can be tightened, against the surface of the beam member 306using nuts 312 to form a compression fit against the grade pins 304.Washers 310 can be provided to distribute forces in the beam member 306in the region of the fasteners 308. Such a configuration can allowadjustment of the beam members 306 vertically with respect to the pins304, while also eliminating components made of wood or other materialwhich could potentially deteriorate over time.

FIG. 10A illustrates one example of a hopper 340 that can be used, insome embodiments. The hopper 340 can be formed from any suitablematerial, including, for example, wood, and can be have any suitableconfiguration to funnel concrete toward the center of a form. As shownin FIG. 10A, the hopper 340 has a generally rectangular inlet thattapers toward, its outlet at the bottom of the hopper 340. The hopper340 can also include a handle 342 that facilitates movement of thehopper 340 from one site to the next. FIG. 10B shows an example of thehopper 340 in place at the top of the frame system 100. As can be seenin FIG. 10B, the hopper 340 can sit at the top of the frame 102, betweenthe two template members 114 and directly above the form 104. In someembodiments, spacer blocks 344 can be placed at each end of the hopper340, between the ends of the hopper 340 and the elongate members 110forming the frame 102. By such a configuration, the outlet of the hopper340 can be positioned above the central region of the form 104 and awayfrom the anchor bolts 116, avoiding unwanted splashing and/or drippingof concrete onto the frame 102, the anchor bolts 116, or the innersurfaces of the form 104 as the concrete is being placed.

FIG. 11A shows a frame system 400 configured in accordance with anotherembodiment. The frame system 400 can generally include a frame 402, aform 404, and a mat and cage assembly 406. The frame 402, the form 404,and the mat and cage assembly 406 can comprise any materials and canhave any configuration suitable for their intended purpose. For example,the frame 402, the form 404, and the mat and cage assembly 406 can havea similar configuration and connection as the frame 102, the form 104,and the mat and cage assembly 106 described above in connection withFIGS. 1-6.

In addition to these components, the frame system 400 can includesupports 450 configured to allow vertical movement of the frame 402relative to the supports 450 while limiting lateral movement of theframe 402 relative to the supports 450. In some embodiments, thesupports 450 can be configured similar to scaffold shoes; i.e., they caninclude externally-threaded pipe extending from feet 452. In someembodiments, the supports 450 can be coupled to the frame 402 byinserting the supports 450 through sleeves 454 disposed on or near theends of the frame 402. Adjustment members 456, such as, for example,wingnuts, can be disposed along each of the supports 450, and can beconfigured to allow adjustment and maintenance of the vertical positionof the frame 402. In some embodiments, the sleeves 454 can be coupled tothe frame 402 at mounting plates 458. The mounting plates 458 may beconnected directly to the frame 402 or, as illustrated in FIG. 11B, themounting plates 458 can be connected to extensions 460 that areconnected to the frame 402, to facilitate desired spacing of thesupports 450 from one another at each end of the frame 402 (and,accordingly, at each end of an excavation).

FIG. 11C is a close-up side view showing in detail the connectionbetween the support 450, the sleeves 454, the mounting plates 458, andthe extensions 460 in the embodiment illustrated in FIGS. 11A and 11B.FIG. 11C also illustrates an adjustment member 456 supporting the sleeve454 from below, thus limiting downward movement of the sleeve 454 (andthe frame coupled to the sleeve 454).

In some embodiments, the supports 450, the sleeves 454, the mountingplates 458, and the extensions 460 can all be formed from the same ordifferent metals. For example, the extensions 460 can be formed fromaluminum C-channel. In various embodiments, the sleeves 454 can bepermanently coupled or removably or adjustably coupled to theirrespective mounting plates 458. The mounting plates 458 can bepermanently coupled (e.g., welded) or removably coupled (e.g., bolted)to the extensions 460. In some embodiments, the sleeves 454 can bedirectly coupled to the frame 402 or to the extensions 460, without theuse of a mounting plate.

The frame system 400 can be particularly advantageous in very largeprojects, allowing dozens or even hundreds of footings to be constructedvery rapidly and in proper alignment without requiring separate gradebeams and pins to be set at each excavation. In use, the entire framesystem 400, including the supports 450 and the extensions 460, can belifted and transported, from excavation to excavation (e.g, using aforklift). Once the system 400 is set down, with the supports 450resting on the ground outside of an excavation and with the form 404 andmat and cage assembly 406 suspended from the frame 402 into theexcavation, the system 400 can be moved into proper alignment (e.g.,using hubs and tack lines according to known methods). The frame can beadjusted to grade using adjustment members 456 to limit downward andupward movement of the frame 402 once it is in position. Stabilizationpins 462 can be inserted through each support 450 and into the ground toprevent lateral movement of the frame system 400. Once inserted, thestabilization pins 462 can be clamped to the supports 450 using a clamp464, such as, for example, a locking bolt. The use of such a clamp 464can help limit or prevent unwanted vertical lift of the frame system 400as concrete is being placed.

With the frame system 400 in its desired position, concrete can beplaced to construct the footing in generally the same manner asdescribed above in connection with FIGS. 1-8E. After the footing isformed, the pins 462 can be pulled out, and the frame 402 and form 404can be separated from the footing in generally the same manner asdescribed above in connection with FIGS. 1-8E. The frame system 400(including the supports 450 and extensions 460) can then be lifted andmoved to another excavation.

Although the examples of frame systems discussed above illustrate framessupporting only one form and mat/cage assembly, various embodiments canbe adapted for use with multiple forms and mat/cage assemblies. Forexample, FIG. 12 illustrates a frame system 500 having multiple forms504 and mat/cage assemblies 506 suspended from the frame 502 in the sameexcavation. In FIG. 12, two forms/assemblies 504/506 are visible left toright, across the width of the page. An embodiment comprising multipleforms/assemblies arranged in a row along a single frame can be used toadvantage in, for example, an installation of a solar parabolic trough.Additional piers can be installed in the same excavation (atop the samefooting) in an array by joining together multiple frames side-to-side.For example, as illustrated in the leftmost portion of FIG. 12 (in whichonly the frame 502 in the front is visible), multiple frames 502 can bejoined together (into the page) in any suitable fashion, by connectingthe ends of the frames 502 with connecting members 510 that are boltedor otherwise secured to the ends of the frames 502. Connecting members510 can comprise, for example, C-channel. As illustrated in therightmost portion of FIG. 12, a given frame system 500 can also beadapted to extend across a larger excavation (illustrated in dashedlines) by connecting one or more extensions 512 to one or both ends ofthe frame system 500, so that the ends of the extension 512 can besupported by grade beams 516(b) and pins 514(b) set outside the largerexcavation (instead of grade beams 516(a) and 514(a) which areillustrated, for the smaller excavation).

FIG. 13 shows an example of how the frame system 100 illustrated inFIGS. 1A-3D can be adapted for use with a different kind of form thanthe form 104. In the embodiment illustrated in FIG. 13, the form 170 canbe a SONOTUBE® form, or other cardboard-based form, without a flangelike the form 104 illustrated in FIG. 4. As shown in FIG. 13, the form170 can be coupled to the attachment member 118 of the frame system 100using one or more adapters 172, which can be angles or clips having asimilar configuration to the bolt clip 124 illustrated in FIG. 6C. Theadapters 172 can be configured such that a vertically-extending leg ofthe adapter 172 can be coupled to the inside of the wall of the form 170at the top of the form 170 (e.g., using a nut and bolt as illustrated),and so that a horizontally-extending leg of the adapter forms a flangethat can be aligned with and coupled to the attachment member 118. Asshown in FIG. 13, a washer 174 can be used on the outside of the form170, between the form and the nut, to distribute forces on the formwhere the adapter 172 couples to the form 170. In some embodiments, forexample embodiments employing relatively larger forms 170, the adapter172 can couple to the elongate member 110 (e.g., to the lower leg of aC-channel) instead of to the attachment member 118. The elongate members110 can include one or more openings 176 to facilitate such aconfiguration. In FIG. 13, concrete inside the form 170 is illustratedby region 178. Region 180 illustrates the coupling (e.g., a plug weld)between the attachment member 118 and the adapter 172.

FIG. 14 is a perspective view illustrating an example of a frame 600configured in accordance with another embodiment. In addition toelongate members 110, crossmembers 112, template members 114, andattachment members 118 as described above in connection with FIG. 1, theframe 600 also includes end members 602 disposed on each end of theframe 600. As shown in FIG. 14, the end members 602 can connect theelongate members 110 at each end of the frame 600, providing additionalstructural integrity to the frame 600 and also facilitating handling ofthe frame 600. The end members 602 can also facilitate measuring ofend-to-end distances between adjacent frames 600 in a series of frames600 (see, e.g., FIG. 7). In some embodiments, the horizontal position ofthe frames 600 (in the lengthwise direction) can be adjusted after theirvertical position is set (either by setting the frame 600 on grade beamsor by setting the frame 600 on adjustable supports as described above inconnection with FIGS. 11A and 11B) by measuring the end-to-end distancesbetween end members 602 of adjacent frames 600. Since the end-to-centerlength of the frames 600 (i.e., the distance between the end of theframes and the location along the frames where the form, template, andinbeds are centered) is a known quantity, the end-to-end distancesbetween adjacent frames can be used to move the form and the inbeds inthe template into proper horizontal position. In some embodiments, theside-to-side distances between adjacent frames in the cross-wisedirection (i.e., a horizontal direction perpendicular to the lengthwisedirection) can also be used to move the form and the inbeds in thetemplate into proper horizontal position.

FIG. 15 is a process diagram illustrating a process 700 for formingconcrete footings in accordance with an embodiment. At block 702, theprocess 700 includes providing a frame assembly comprising a frame, aform, and a template, for example as described above in connection withFIG. 1-6C. The frame assembly can also include a concrete reinforcementstructure, such as a mat and cage assembly, part or all of which can bedisposed within the frame. At block 704, the process includes couplingat least one inbed to the template. At block 704, any number of inbedscan be coupled to the template, in any suitable pattern for theparticular application, and in any suitable fashion. For example, insome embodiments, two anchor bolt inbeds can be coupled to each of twotemplates, in a generally rectangular pattern, by inserting each inbedthrough a hole in the template and removably securing the inbed to thetemplate using a nut. At block 706, the process includes positioning theframe assembly (possibly including the reinforcement structure, ifpresent) over an excavation, for example as described above inconnection with FIGS. 8A and 8B. Positioning the frame assembly over anexcavation can include suspending the form, and concrete reinforcingstructure into an excavation. At block 708, the process includes placingconcrete into the form. Placing concrete into the form can includepouring concrete through one or more openings in the frame assembly suchthat the concrete enters the form. Concrete can be placed until itreached a desired position with respect to the form, at which point thetop of the concrete is also at a desired elevation for the constructionsite. Optionally, this process can also include releasing the inbedsfrom the template, separating the form from the hardened concrete, andremoving the form and template from the excavation.

FIG. 16 is a process diagram illustrating another process 720 forforming concrete footings in accordance with another embodiment. Atblock 722, the process 720 includes placing a form, a template, aconcrete reinforcing structure, and one or more inbeds, for example asdescribed above in connection with FIGS. 1-6C, into an excavationsimultaneously. These components can be placed in the excavationsimultaneously because the positions of these components can be fixedwith respect to one another, at least during this step. Placing thesecomponents into an excavation can include suspending the form and/or theconcrete reinforcing structure from a frame or other supportingstructure. In some embodiments, placing these components into anexcavation simultaneously can result in the form being positionedvertically at the desired elevation for the particular constructionsite. At block 724, the process 720 includes adjusting the horizontalposition of the form, the template, the reinforcing structure, and theinbed(s). The horizontal positions of these components can be adjustedsimultaneously, as the positions of these components can be fixed withrespect to one another, at least during this step. At block 708, theprocess includes placing concrete into the form. Placing concrete intothe form can include pouring concrete through one or more openings inthe frame assembly such that the concrete enters the form. Concrete canbe placed until it reached a desired position with respect to the form,at which point the top of the concrete is also at a desired elevationfor the construction site. Optionally, this process can also includereleasing the inbeds from the template, separating the form from thehardened concrete, and removing the form and template from theexcavation.

These and other embodiments can be used to advantage in a wide varietyof construction applications, including, for example, wind farminstallations, solar technology installations, stadium bleachers, andlight pole bases.

Although the foregoing has been described in detail by way ofillustrations and examples for purposes of clarity and understanding, itis apparent to those skilled in the art that certain changes andmodifications may be practiced. Therefore, the description and examplesshould not be construed as limiting the scope of the invention to thespecific embodiments and examples described herein, but rather to alsocover all modification and alternatives coming with the true scope andspirit of the invention. Moreover, not all of the features, aspects andadvantages described herein above are necessarily required to practicethe present invention.

What is claimed is:
 1. A method of forming a concrete spread footing inan excavation, the method comprising: providing a frame assemblycomprising: a frame configured to extend over the excavation from afirst side of the excavation to an opposing second side of theexcavation; a form coupled to the frame, the form configured to defineat least part of the shape of the concrete spread footing; areinforcement structure configured to reinforce the concrete spreadfooting, at least part of the reinforcement structure being disposedwithin the form; and a template defining an inbed pattern over the form;wherein the frame is configured to support the form and thereinforcement structure in suspension over the excavation; wherein theframe comprises at least one attachment member configured to couple tothe frame and the form, the at least one attachment member beingdisposed vertically below the template and spaced apart vertically fromthe template by a sufficient distance to allow workers' hands to accessthe space vertically between the at least one attachment member and thetemplate.
 2. The method of claim 1, further comprising placing the frameon in-ground supports disposed on first and second sides of theexcavation.
 3. The method of claim 1, further comprising providing atleast one inbed, the at least one inbed being releasably coupled to thetemplate.
 4. The method of claim 1, further comprising placing concreteinto the form so as to form the concrete spread footing, whereby the atleast one inbed is cast in place.
 5. The method of claim 4, furthercomprising decoupling the template from the at least one inbed.
 6. Themethod of claim 1, further comprising separating the form and the framefrom the concrete spread footing.
 7. The method of claim 1, wherein theconcrete spread footing comprises a pier.
 8. The method of claim 7,wherein the form is configured to define the shape of the pier.
 9. Themethod of claim 4, further comprising forming a second concrete spreadfooting in a second excavation using the frame assembly.
 10. A method offorming a concrete spread footing in an excavation, the methodcomprising: providing a frame assembly comprising: a frame configured toextend over the excavation from a first side of the excavation to anopposing second side of the excavation; a form configured to define atleast part of the shape of the concrete spread footing; an attachmentmember configured to operatively couple the form to the frame; areinforcement structure configured to reinforce the concrete spreadfooting, at least part of the reinforcement structure configured to bedisposed within the form; and a template defining an inbed pattern overthe form; wherein the at least one attachment member and the templatetogether define a working space configured to allow access of workers'hands to the working space, thereby allowing for manual decoupling ofthe form from the frame; coupling at least one inbed to the template;and suspending the form and the reinforcement structure from the frameover the excavation, whereby the concrete spread footing can be formedby placing concrete into the form.
 11. The method of claim 10, whereinsuspending the form and the reinforcement structure from the framecomprises placing the frame on in-ground supports disposed on first andsecond sides of the excavation.
 12. The method of claim 11, wherein thein-ground supports are set to grade before the frame is placed on thesupports.
 13. The method of claim 10, further comprising placingconcrete into the form so as to form the concrete spread footing,whereby the at least one inbed is cast in place.
 14. The method of claim10, wherein the reinforcement structure is releasably coupled to theframe.
 15. The method of claim 10, further comprising separating theframe and the form from the concrete spread footing.
 16. The method ofclaim 10, wherein the frame and the form are configured to remaincoupled to one another as they are separated from the concrete spreadfooting.
 17. The method of claim 13, further comprising forming a secondconcrete footing in a second excavation using the frame assembly. 18.The method of claim 10, further comprising decoupling the form from theframe.
 19. A method of forming a concrete spread footing in anexcavation, the method comprising: providing a frame configured toextend over the excavation from a first side of the excavation to anopposing second side of the excavation; operatively coupling a form tothe frame via an attachment member, the form being configured to defineat least part of the shape of the concrete spread footing; providing areinforcement structure configured to reinforce the concrete spreadfooting, at least part of the reinforcement structure being disposedwithin the form; providing a template defining an inbed pattern over theform, the template being spaced apart vertically from the attachmentmember by a sufficient distance to allow workers' hands to access theattachment member; coupling at least one inbed to the template;suspending the form and the reinforcement structure from the frame intothe excavation; and placing concrete into the form so as to form theconcrete spread footing, whereby the at least one inbed is cast inplace.
 20. The method of claim 19, further comprising manually accessingthe attachment member so as to decouple the form from the frame.